Fabric joining using discontinuous adhesive seam

Abstract

Systems and methods are described that provide for automated manufacturing of garments using cutting, folding tools and adhesive dispensers operating on continuous webs of fabric webs to manufacture garments in an efficient manner while improving quality and overcoming material handling issues resulting from the properties of fabrics.

What is claimed is: 
     
         1 . A joined fabric assembly comprising:
 a first portion of fabric material;   a second portion of fabric material;   a first plurality of discrete masses of adhesive material aligned in a first bondline, the first plurality of discrete masses of adhesive material securing the first portion of fabric material to the second portion of fabric material to form a seam; and   a second plurality of discrete masses of adhesive material aligned in a second bondline that follows the first bondline, the second plurality of discrete masses of adhesive material forming part of the seam, at least one or more of the second plurality of discrete masses having at least one or more characteristics selected from the group consisting of adhesive property, size, color, pitch, grouping, shape and orientation that is different than at least one or more of the first plurality of discrete masses.   
     
     
         2 . The joined fabric assembly of  claim 1 , wherein the first portion of fabric material and the second portion of fabric material are connected by a fold, wherein the first plurality of discrete masses joining the first and second portions of fabric material to form a hem or dart. 
     
     
         3 . The joined fabric assembly of  claim 1 , wherein the first portion of fabric material further comprises a shirt back and the second portion of fabric comprises a shirt front or a yoke. 
     
     
         4 . The joined fabric assembly of  claim 1 , wherein the first portion of fabric material further comprises a shirt component selected from the group consisting of a banding, binding, a casing, a facing, a liner, a collar, a collar stand, a button stand, a shirt front, a yoke, a shirt back, a sleeve, a placket, and a cuff. 
     
     
         5 . The joined fabric assembly of  claim 1 , wherein one or more of the first plurality of discrete masses of adhesive material further comprises:
 a substantially spherical dome shape.   
     
     
         6 . The joined fabric assembly of  claim 1 , wherein one or more of the first plurality of discrete masses of adhesive material further comprises:
 a substantially elongated shape.   
     
     
         7 . The joined fabric assembly of  claim 6 , wherein at least two of adjacent elongated shapes have an orientation that are aligned in substantially co-linear with a direction of the seam. 
     
     
         8 . The joined fabric assembly of  claim 6 , wherein at least two of adjacent elongated shapes are oriented in a first direction that is different than a direction of the seam. 
     
     
         9 . The joined fabric assembly of  claim 1 , wherein the first plurality of discrete masses of adhesive material further comprises:
 a first group of discrete masses forming a first portion of the first bondline having a first pitch and a first adhesive mass; and   a second group of discrete masses forming a first portion of the first bondline having a second pitch and a second adhesive mass, wherein the first pitch and/or the first adhesive mass is different than the second pitch and/or the second adhesive mass.   
     
     
         10 . The joined fabric assembly of  claim 1 , wherein the first plurality of discrete masses of adhesive material further comprises:
 a group of discrete masses forming a portion of the first bondline has a first pitch and a first adhesive mass; and   a second plurality of discrete masses of adhesives forming a second seam with the first portion of fabric material, the second plurality of discrete masses having a second pitch and a second adhesive mass, wherein the first pitch and/or the first adhesive mass is different than the second pitch and/or the second adhesive mass.   
     
     
         11 . The joined fabric assembly of  claim 1 , wherein the first plurality of discrete masses of adhesive material further comprises at least two masses having different shapes. 
     
     
         12 . The joined fabric assembly of  claim 1 , wherein the first plurality of discrete masses of adhesive material further comprises at least two masses having different color. 
     
     
         13 . The joined fabric assembly of  claim 1 , wherein the first plurality of discrete masses of adhesive material further comprises at least two masses having different orientations. 
     
     
         14 . The joined fabric assembly of  claim 1 , wherein a first discrete mass of the discrete masses of adhesive material forming the first bondline is fully aligned with a second discrete mass of the discrete masses of adhesive material forming the second bondline, wherein the first discrete mass is closer to the second discrete mass than another one of the discrete masses of adhesive material forming the second bondline. 
     
     
         15 . The joined fabric assembly of  claim 1 , wherein a first discrete mass of the discrete masses of adhesive material forming the first bondline is partially aligned with a second discrete mass of the discrete masses of adhesive material forming the second bondline, wherein the first discrete mass is closer to the second discrete mass than another one of the discrete masses of adhesive material forming the second bondline. 
     
     
         16 . The joined fabric assembly of  claim 1 , wherein a first discrete mass of the discrete masses of adhesive material forming the first bondline is not aligned with a second discrete mass of the discrete masses of adhesive material forming the second bondline, wherein the first discrete mass is closer to the second discrete mass than another one of the discrete masses of adhesive material forming the second bondline. 
     
     
         17 . The joined fabric assembly of  claim 1 , wherein the first bondline has a first wave form. 
     
     
         18 . The joined fabric assembly of  claim 17 , wherein the second bondline has a second wave form. 
     
     
         19 . The joined fabric assembly of  claim 18 , wherein the first wave form intersects the second wave form. 
     
     
         20 . The joined fabric assembly of  claim 1 , wherein the first bondline has a plurality of loops.